Plate swirler with converging swirl passages

ABSTRACT

A swirler includes a swirler body defining a longitudinal axis. A stack of swirler plates is assembled to the swirler body stacked in a direction along the longitudinal axis. Each of the swirl plates defines a vane portion. The swirler plates are mounted rotated circumferentially about the longitudinal axis relative to neighboring ones of the swirler plates so the vane portions form a swirler vane.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/996,510 filed Jan. 15, 2016, the contents of which are incorporatedby reference herein in their entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to swirlers for inducing swirl on flowingfluids, and more particularly to swirlers for air or other fluids suchas used in atomizers, fuel injectors for gas turbine engines, and thelike.

2. Description of Related Art

A variety of devices and methods are known in the art for swirlingfluids such as air. Swirlers in air and fuel flow passages can be usedin fuel injection, for example, where the swirl induced on the fuel andair atomizes the fuel for combustion. Air swirlers for gas turbineengines are required to be designed for efficiency, and formanufacturability. The designs must also be tolerant of a high degree ofthermally induced stresses.

Conventional methods and systems have generally been consideredsatisfactory for their intended purpose. However, there is still a needin the art for improved swirlers. The present disclosure provides asolution for this need.

SUMMARY OF THE INVENTION

A swirler includes a swirler body defining a longitudinal axis. A stackof swirler plates is assembled to the swirler body stacked in adirection along the longitudinal axis. Each of the swirl plates definesa vane portion. The swirler plates are mounted rotated circumferentiallyabout the longitudinal axis relative to neighboring ones of the swirlerplates so the vane portions form a swirler vane.

The swirler body can defines an annular flow passage therethrough. Thestack of swirler plates can be mounted within the annular flow passageto impart swirl on fluids flowing through the annular flow passage.

Each of the swirler plates can include a plurality of vane portions,wherein respective vane portions of the swirler plates form a pluralityof respective swirler vanes. Each of the swirler plates can include aperipheral ring, wherein the vane portions of the swirler plates extendradially inward from the respective peripheral rings. Each swirler platecan include at least one alignment tongue engaged with an alignmentgrove defined in the swirler body for registration of the swirler platesto form the swirler vane. The alignment tongue of each swirler plate canbe positioned circumferentially relative to the respective vane portionin a circumferential location common to all of the swirler plates,wherein the alignment grove of the swirler body is profiled to definethe swirler vane by registration of the alignment tongues with thealignment groove.

The swirler plates can be identical to one another. An end swirler platecan be included at one end of the stack of swirler plates, wherein theend swirler plate includes a swirl vane portion positioned to form partof the swirl vane, wherein the end swirler plate differs from theswirler plates of the stack of swirler plates in at least one ofmaterial or axial thickness. It is also contemplated that each swirlerplate defines a swirl passage therethrough, and wherein the swirlpassage of each successive swirler plate has a reduced size relative tothat of a preceding one of the swirler plates in the direction along thelongitudinal axis to define a converging swirl flow path through thestack of swirler plates.

A nozzle includes a nozzle body including a swirler as in any of theembodiments described above, wherein the swirler defines an air circuit,and wherein the nozzle body defines a liquid circuit, and wherein theliquid and air circuits are configured for air blast atomization of aspray issued form the liquid circuit. The air circuit can be an innerair circuit inboard of the liquid circuit or an outer air circuitoutboard of the liquid circuit, for example.

A method of making a swirler includes engaging a stack of swirler plateswith a swirler body defining a longitudinal axis with each swirler platerotated circumferentially about the longitudinal axis relative toneighboring ones of the swirler plates so vane portions of the swirlerplates form one or more swirler vanes. The method can include formingthe stack of swirler plates with the plates stacked using at least oneof electrical discharge machining, water jet machining, conventionalcutting (e.g., machining), sheet metal processing (e.g.,stamping/cutting/punching), laser cutting, metal injection molding(MIM), additive manufacturing or regular sintering, and/or etching toform one or more flow passages through the stack. Engaging the stack ofswirler plates can include sliding the stack of swirler plates intoengagement with an alignment groove of the swirler body followed byjoining of one or more of the swirler plates to the swirler body tosecure the stack of swirler plates to the swirler body. It is alsocontemplated that the assembly can be done without a tongue/groovestructure. This can be done, for example, by aligning the stackedswirler through assembly fixturing, and then joining the swirlertogether, e.g., through braze. Then the assembly fixture can then beremoved.

These and other features of the systems and methods of the subjectdisclosure will become more readily apparent to those skilled in the artfrom the following detailed description of the preferred embodimentstaken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosureappertains will readily understand how to make and use the devices andmethods of the subject disclosure without undue experimentation,preferred embodiments thereof will be described in detail herein belowwith reference to certain figures, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a stack ofswirler plate blanks constructed in accordance with the presentdisclosure;

FIG. 2 is a perspective view of the stack of FIG. 1, showing the stackafter the blanks have been formed into swirler plates;

FIG. 3 is an axial end view of the stack of swirler plates of FIG. 2,showing the swirler plates rotated relative to one another to form thevane portions into swirler vanes;

FIG. 4 is an exploded perspective view of the stack of swirler plates ofFIG. 2, showing the swirler body with alignment groves for registeringthe swirler plates into the rotated swirler configuration shown in FIG.3;

FIG. 5 is a perspective view of the assembled swirler body and swirlerplates of FIG. 4, showing the swirler plates registered in positionwithin the swirler body, with the swirler portions of the swirler platesforming swirl vanes;

FIGS. 6-8 are inlet end elevation, cross-sectional side elevation, andoutlet end elevation views, respectively, of another exemplaryembodiment of a swirler in accordance with this disclosure, showing astack of swirler plates where the swirl passages are narrower andnarrower from plate to plate to form converging swirl passages;

FIGS. 9-10 are partially cut-away side elevation and perspective views,respectively, of another exemplary embodiment of a swirler in accordancewith this disclosure, showing a vane angle achieved with the stack ofswirler plates that is difficult or impossible to attain withtraditional cutting processes;

FIGS. 11-13 are inlet end elevation, cross-sectional side, and cut-awayperspective views, respectively, of another exemplary embodiment of astack of swirler plates in accordance with this disclosure, showingcylindrical flow passages with enlarged inlet openings;

FIGS. 14-15 are a perspective and cross-sectional perspective views,respectively, of another exemplary embodiment of a stack of swirlerplates in accordance with this disclosure, showing a stack with acentral, cylindrical body, and peripheral rings that can serve as a heatshield or the like;

FIGS. 16-17 are exploded perspective and cross-sectional perspectiveviews, respectively, of another exemplary embodiment of a stack ofswirler plates in accordance with this disclosure, showing a stack witha central, cylindrical body without peripheral rings, and havingoptional leading and trailing edge cones; and

FIG. 18 is a schematic side elevation view of an exemplary nozzleconstructed in accordance with the present disclosure, showing inner andouter air swirlers formed using stacks of swirler plates.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectdisclosure. For purposes of explanation and illustration, and notlimitation, a partial view of an exemplary embodiment of a swirler inaccordance with the disclosure is shown in FIG. 1 and is designatedgenerally by reference character 100. Other embodiments of swirlers inaccordance with the disclosure, or aspects thereof, are provided inFIGS. 2-18, as will be described. The systems and methods describedherein can be used to provide swirlers for imparting swirl on a flow offluid, for example for swirling air in fuel injectors for gas turbineengines.

A method of making a swirler 100 includes starting with a stack 102 ofblanks 104. Blanks 104 in this example are identical to one another andare in the shape of cylindrical wafers. An end plate 106 is included,which is thicker in the axial direction of longitudinal axis A than theblanks 104, but otherwise identical in geometry. A cut pattern isindicated in broken lines in FIG. 1. The method includes cutting theblanks 104 and 106 along the pattern indicated in FIG. 1 to form a stack102 of swirler plates 108 and 110 shown in FIG. 2, where swirler plate110 is identical to swirler plates 108 except for its axial thickness,corresponding to end plate 106 of FIG. 1. Given the geometry of theswirler plates 108 and 110, it is possible to efficiently perform thecutting with all of the blanks 104 and 106 stacked together so all arecut with a single cutting operation, e.g., simultaneously. This cuttingprocess can employ any suitable process such as electrical dischargemachining, water jet machining, conventional cutting (e.g., machining),sheet metal processing (e.g., stamping/cutting/punching), laser cutting,metal injection molding (MIM), additive manufacturing or regularsintering, and/or etching. The cutting operation forms one or more flowpassages 112 through the stack 102. Between each circumferentiallyadjacent pair of flow passages 112 there is a vane portion 114 definedin each swirler plate 108 and 110. Each of the swirler plates 108 and110 includes a plurality of vane portions 114. Each of the swirlerplates 108 and 110 includes a peripheral ring 116, wherein the vaneportions 114 of the swirler plates 108 and 110 extend radially inwardfrom the respective peripheral rings 116.

With reference to FIG. 3, the swirler plates 108 and 110 are shownrotated circumferentially about the longitudinal axis A relative toneighboring ones of the swirler plates 108 and 110 so the vane portions114 form respective swirler vanes 118. Thus when a flow of air or otherfluid is conducted through swirl passages 112, swirl will be imparted onthe flow by vanes 118.

With reference now to FIG. 4, the method includes engaging a stack 102of swirler plates 108 and 110 with a swirler body 122 defining alongitudinal axis with each swirler plate rotated circumferentiallyabout the longitudinal axis A as described above with reference to FIG.3. Each swirler plate 108 and 110 includes alignment tongues 120. Thesealignment tongues engage with respective alignment grooves 124 definedin the swirler body 122 for registration of the swirler plates 108 and110 to form the swirler vanes as shown in FIG. 3. In other words,alignment grooves 124 are profiled to wind about axis A so that whenalignment tongues 120 engage alignment grooves 124, each swirler plate108 and 110 is rotated circumferentially to the proper position to formswirl vanes 118. Engaging the stack of swirler plates 102 includessliding the stack of swirler plates into engagement in an axialdirection relative to longitudinal axis A, with alignment tongues 120sliding along alignment grooves 124 of the swirler body. When the stack102 has reached the end of alignment grooves 124, one or more of theswirler plates 108 and 110 can be joined by any suitable joining processto the swirler body to secure the stack 102 to the swirler body 122. Itis also contemplated that the assembly can be done without atongue/groove structure. This can be done, for example, by aligning thestacked swirler through assembly fixturing, and then joining the swirlertogether, e.g., through braze. Then the assembly fixture can then beremoved. It is also contemplated that the swirler plates 104 can befused together, e.g., if metallic plates are used they can be heat fusedtogether.

FIG. 5 shows the stack 102 assembled into swirler body 122 to formswirler 100. The swirler body 122 defines an annular flow passage 126therethrough. The stack 102 of swirler plates 108 and 118 is mountedwithin the annular flow passage 126 to impart swirl on fluids flowingthrough the annular flow passage 126.

The alignment tongue 120 of each swirler plate 108 and 110 is positionedcircumferentially relative to the respective vane portions 114 in acircumferential location common to all of the swirler plates 108 and110, and it is the alignment groves 124 of the swirler body 122 that areprofiled to define the swirler vanes 118 by registration of thealignment tongues 120 with the alignment grooves 124. However, thoseskilled in the art will readily appreciate that any other suitableconfiguration can be used, for example, if straight alignment grooveswere to be used, the circumferential positions of the alignment tonguescan vary from plate to plate in the stack to provide the desired vanecontour.

Referring now to FIGS. 6-8, another embodiment of a swirler 200 is shownwhere the swirler plates 210 in stack 202 are not all identical, rathereach plate is unique within stack 202. Each swirler plate 210 defines aswirl passage 212 therethrough, and wherein the portion of swirl passage212 of each successive swirler plate 210 has a reduced size relative tothat of a preceding one of the swirler plates in the direction along thelongitudinal axis A to define a plurality of converging swirl flow paths212 through the stack of swirler plates 212. The converging profile offlow passages 212 can be seen in the cross-section of FIG. 7, where theinlets shown in FIG. 6 are larger than the outlets shown in FIG. 8. Inaddition to varying the geometry of some or all of the swirler plates ofa stack as described herein, it is also contemplated that the materialscan be varied from swirler plate to swirler plate within a stack. Forexample, one or two of the swirler plates 204 (such as the right-mosttwo swirler plates 204 as oriented in FIG. 7) can be made of a heatresistant material such as ceramic, whereas the remaining swirler plates204 can be made of a less heat tolerant material such as a metal. Thisway if used in a gas turbine engine, for example, the more heat tolerantswirler plates 204 will provide heat shielding for the less heattolerant swirler plates 204.

With reference now to FIGS. 9 and 10, using stacks of swirler plates asdisclosed herein can provide design freedoms relative to traditionalswirler designs. For example, in swirler 300, the stack 302 of swirlerplates has vanes 318 with such a high swirl angle θ, e.g., about 75°,and wherein the depth of the vanes 318 is such that at that angle θ,traditional cutting techniques can not be used to form the vanes 318.However, using the stack 302 of swirler plates, such high swirl anglescan be achieved by simply providing the circumferential rotation of theswirl plates in stack 302 needed to achieve the desired angle.

With reference now to FIGS. 11-13, any suitable cross-sectional shapecan be used for the flow passages. In embodiments described above,swirlers have flow passages where the cross sectional shape of the flowpassages is a triangular segment (as shown in FIG. 3) or quadrilateralsegment shaped (as shown in FIG. 8). In swirler 400 of FIGS. 11-13, asimilar stack of swirler plates is shown to those described above,however the flow passages 418 are cylindrical and the first two plateshave an enlargement in the flow passage 418 to provide an entrance thatenhances flow through the flow passages 418. The plates are shown as asolid stack prior to relative rotation of the plates, however the platesare shown separately and rotated relative to one another in FIG. 13.

With reference now to FIGS. 14-15, another exemplary embodiment of astack 502 of swirler plates 504 is shown, similar to those shown in FIG.3 but with a cylindrical center body 550 included in each swirler plate504. FIGS. 16-17 show yet another exemplary embodiment of a stack 602 ofswirler plates 604 in which the peripheral rings described above areomitted. Additionally, leading and trailing edge cones 652 and 654 canoptionally be mounted to center body 650 as needed to provide a givenset of flow characteristics.

With reference now to FIG. 18, a nozzle 10 includes swirlers 12 and 14as described above, wherein each swirler defines a respective aircircuit 16 and 18. The body of nozzle 10 defines a liquid circuit 20radially between the swirlers 12 and 14. The liquid and air circuits 16,18, and 20 are configured for air blast atomization of a spray issuedform the liquid circuit. This can be used, for example, to atomize fuelfor fuel injection in a gas turbine engine. The air circuit 18 inboardof the liquid circuit 20 includes an inner air swirler 14, which can beconfigured as shown in FIG. 3, 14, or 16, for example. The air circuit16 outboard of the liquid circuit 20 includes an outer air swirler 12which can be configured as shown in FIG. 6,10, or 13, for example, wherea central aperture accommodates inboard components including the liquidcircuit 20 and inner air circuit 18.

Potential advantages of using swirler plates stacked as disclosed hereininclude ease of manufacturing, wherein multiple plates can be cut in asingle operation by cutting an entire stack of plates at once using anEDM or water jet cutting process, or any other suitable process. Ease ofassembly is another potential advantage. As described above, there arealso potential advantages provided in design flexibility, wheregeometries not feasible with traditionally technique can be obtained.Another potential advantage is seen through the use of multiplematerials where the majority of the plates can be made out of low costmaterial, while more specialized (but higher cost) materials can be usedonly where needed (such as flame-facing plates). This allows for anoverall lower cost swirler than if it was all required to be made out ofspecial high temperature materials. Additional tailoring of materials tosuit opposing design constraints can see further advantages. Forinstance, perhaps the high oxidizing plates can be used for downstream(e.g., flame facing) surfaces, while upstream surfaces can be made ofhigher strength (but lower oxidizing) materials can result in a swirlerthat is heat tolerant where needed but also high strength where alsoneeded.

One further potential advantage may be seen with part commonality tosave cost. For example, one set of plates can be made which can be usedin a family of air swirlers of varying swirl angle, where the plates areidentical (and therefore cheaper due to mass production) and only thealignment groove or alignment fixturing changes between swirlers.

The methods and systems of the present disclosure, as described aboveand shown in the drawings, provide for swirlers with superior propertiesincluding ease of manufacture and geometries difficult or impossible toattain with traditional cutting processes. While the apparatus andmethods of the subject disclosure have been shown and described withreference to preferred embodiments, those skilled in the art willreadily appreciate that changes and/or modifications may be made theretowithout departing from the scope of the subject disclosure.

What is claimed is:
 1. A swirler for a gas turbine comprising: a swirlerbody defining a longitudinal axis; and a stack of swirler plates,wherein the stack of swirler plates comprises a first swirler plate, asecond swirler plate and a third swirler plate, wherein each swirlerplate defines a vane portion and a swirl passage, wherein the stack ofswirler plates are stacked in the swirler body in a direction along thelongitudinal axis, wherein the first swirler plate abuts the secondswirler plate and the second swirler plate abuts the third swirler platesuch that the swirl passage of the first swirler plate, the swirlpassage of the second swirler plate, and the swirl passage of the thirdswirler plate are aligned to define a swirl flow path through the stackof swirler plates and wherein the vane portion of the first swirlerplate, the vane portion of the second swirler plate, and the vaneportion of the third swirler plate are aligned forming a swirler vaneextending through the stack of swirler plates, wherein the swirl passageof the first swirler plate is larger than the swirl passage of thesecond swirler plate and the swirl passage of the second swirler plateis larger than the swirl passage of the third swirler plate such thatthe swirl flow path through the stack of swirler plates converges,wherein the stack of swirler plates are rotated circumferentially aboutthe longitudinal axis such that the vane portion of each swirler plateis offset circumferentially from adjacent vane portions of adjacentswirler plates.
 2. A nozzle comprising: a nozzle body including theswirler as recited in claim 1, wherein the swirl flow path defines anair circuit, and wherein the nozzle body defines a liquid circuit, andwherein the liquid and air circuits are configured for air blastatomization of a spray issued form the liquid circuit.
 3. The nozzle asrecited in claim 2, wherein the air circuit is an inner air circuitinboard of the liquid circuit.
 4. The nozzle as recited in claim 2,wherein the air circuit is an outer air circuit outboard of the liquidcircuit.
 5. A method of making the swirler as recited in claim 1comprising: engaging the stack of swirler plates with the swirler body.6. The method as recited in claim 5, further comprising forming theswirler plates of the stack of swirler plates using at least one ofelectrical discharge machining, water jet machining, conventionalcutting, sheet metal processing, laser cutting, metal injection molding(MIM), additive manufacturing or sintering, and/or etching.
 7. Themethod as recited in claim 5, wherein engaging the stack of swirlerplates with the swirler body includes sliding the stack of swirlerplates into engagement with an alignment groove of the swirler bodyfollowed by joining one or more of the swirler plates to the swirlerbody to secure the stack of swirler plates to the swirler body.